U.S. patent application number 14/329265 was filed with the patent office on 2016-01-14 for organoclay compositions having quaternary ammonium ion having one or more branched alkyl substituents.
This patent application is currently assigned to ELEMENTIS SPECIALTIES, INC.. The applicant listed for this patent is Elementis Specialties, Inc.. Invention is credited to Yanhui CHEN, David DINO, Wouter IJDO, Edward MAGAURAN.
Application Number | 20160009899 14/329265 |
Document ID | / |
Family ID | 55067096 |
Filed Date | 2016-01-14 |
United States Patent
Application |
20160009899 |
Kind Code |
A1 |
IJDO; Wouter ; et
al. |
January 14, 2016 |
Organoclay Compositions Having Quaternary Ammonium Ion Having One
Or More Branched Alkyl Substituents
Abstract
An organoclay composition where a phyllosilicate clay is
exchanged with quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein at least one of
R.sup.1, R.sup.2 and R.sup.3 is a mixture of branched alkyl
groups.
Inventors: |
IJDO; Wouter; (Yardley,
PA) ; DINO; David; (Cranbury, NJ) ; CHEN;
Yanhui; (Plainsboro, NJ) ; MAGAURAN; Edward;
(Westampton, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Elementis Specialties, Inc. |
East Windsor |
NJ |
US |
|
|
Assignee: |
ELEMENTIS SPECIALTIES, INC.
East Windsor
NJ
|
Family ID: |
55067096 |
Appl. No.: |
14/329265 |
Filed: |
July 11, 2014 |
Current U.S.
Class: |
106/487 |
Current CPC
Class: |
C08K 5/19 20130101; C08K
9/04 20130101; C09D 163/00 20130101; C09D 7/63 20180101 |
International
Class: |
C08K 5/19 20060101
C08K005/19; C08K 3/34 20060101 C08K003/34 |
Claims
1. An organoclay composition comprising: a phyllosilicate clay; and
quaternary ammonium ions having a formula of
[N--R.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein one or more of
R.sup.1, R.sup.2 and R.sup.3 is a mixture of branched alkyl groups,
each branched alkyl group having 12 to 22 total carbon atoms, a
linear backbone and one or more C.sub.1 to C.sub.3 branching alkyl
groups, wherein said branching alkyl groups are distributed at
different carbon positions along the linear backbone of the
branched alkyl group; and wherein when one or more of R.sup.2 and
R.sup.3 is not a branched alkyl group, R.sup.2 and R.sup.3 are a
first linear alkyl group having 1 to 22 carbon atoms, wherein
R.sup.4 is selected from the group consisting of a second linear
alkyl group having 1 to 6 carbon atoms, an aryl group, and
combinations thereof.
2. The composition according to claim 1, wherein R.sup.1 is a
mixture of branched alkyl groups.
3. The composition according to claim 1, wherein R.sup.1 and
R.sup.2 are each a mixture of branched alkyl groups.
4. The composition according to claim 1, wherein R.sup.1, R.sup.2
and R.sup.3 are each a mixture of branched alkyl groups.
5. The composition according to claim 1, wherein one or more of
R.sup.2 and R.sup.3 are each a linear alkyl group having 1 to 22
total carbon atoms.
6. The composition according to claim 5, wherein one or more of
R.sup.2 and R.sup.3 are each a linear alkyl group having 12 to 22
total carbon atoms.
7. The composition according to claim 5, wherein one or more of
R.sup.2 and R.sup.3 are each a linear alkyl group having 1 to 6
total carbon atoms.
8. The composition according to claim 1, wherein R.sup.4 is
independently selected from the group consisting of a benzyl group,
a methyl group, an ethyl group, a propyl group, a butyl group, a
pentyl group or a hexyl group.
9. The composition according to claim 1, wherein one of R.sup.2,
R.sup.3 and R.sup.4 is methyl.
10. The composition according to claim 1, wherein R.sup.2 and
R.sup.3 are methyl and R.sup.4 is benzyl.
11. The composition according to claim 1, wherein an average number
of branches per branched alkyl group is at least 0.7.
12. The composition according to claim 1, wherein an average number
of branches per branched alkyl group ranges from 0.7 to 7.
13. The composition according to claim 1, wherein each branched
alkyl group has a distribution of branching points distributed
along the linear backbone of the branched alkyl group ranging from
a 2 carbon atom position on the linear backbone, counting from a 1
carbon atom position which is bonded to N.sup.+, to a .omega.-2
carbon atom position, where .omega. is a terminal carbon atom
position on the linear backbone.
14. The composition according to claim 1, wherein each branched
alkyl group has 12 to 18 carbon atoms.
15. The composition according to claim 1, wherein each branched
alkyl group has 14 to 18 carbon atoms.
16. The composition according to claim 1, wherein the linear
backbone contains less 0.5 atom % of quaternary carbon atoms.
17. The composition according to claim 1, wherein the linear
backbone is substantially free of quaternary carbon atoms.
18. The composition according to claim 1, wherein a methyl branch
is at least 50% of the branching alkyl groups based on the total
number of branches.
19. The composition according to claim 1, wherein the
phyllosilicate clay comprises a smectite clay.
20. The composition of claim 19, wherein said smectite clay is
selected from the group consisting of: montmorillonite, bentonite,
hectorite, saponite, stevensite and beidellite.
21. The composition of claim 19, wherein said smectite clay is
selected from bentonite and hectorite, and mixtures thereof.
22. The composition of claim 1, wherein having sufficient
quaternary ammonium ions to satisfy 50 to 150 percent of
phyllosilicate cation exchange capacity.
23.-72. (canceled)
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an organoclay composition
wherein a phyllosilicate clay is exchanged with a quaternary
ammonium ion having one or more branched alkyl substituents.
BACKGROUND OF THE INVENTION
[0002] Organoclays have been widely utilized as rheology modifiers
for paint and coatings, inks, greases, oil well drilling fluids to
increase the viscosity of such system. Organoclays find also use as
additives in plastics to improve a variety of properties such as
barrier, mechanical, anti-static and flame retardant properties.
Organoclay are typically prepared by the reaction of an organic
cation, in particular a quaternary ammonium ion, with a clay in
various methods known in the art. If the organic cation contains at
least one alkyl group containing at least 8 to 22 carbon atoms,
then such organoclays have the property of increasing viscosity in
organic based systems. The viscosity increasing properties can be
modified by changing the substituents of the quaternary ammonium
ion. For example, reports describe that the viscosity efficiency of
organoclays was increased by substituting an alkyl group of the
quaternary ammonium ion with a 2-hydroxyethyl group, a
polyoxyethylene group and ester groups. However, the previously
described organoclay compositions do not address the problems
associated with viscosity increase of paint and coatings, inks,
greases, oil well drilling fluids with decreasing temperature.
SUMMARY OF THE INVENTION
[0003] In one embodiment, the present disclosure provides for an
organoclay composition comprising: a phyllosilicate clay; and
quaternary ammonium ions having a formula of
[N--R.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein one or more of
R.sup.1, R.sup.2 and R.sup.3 is a mixture of branched alkyl groups,
each branched alkyl group having 12 to 22 total carbon atoms, a
linear backbone and one or more C.sub.1 to C.sub.3 branching alkyl
groups, wherein the branching alkyl groups are distributed at
different carbon positions along the linear backbone of the
branched alkyl group; and wherein when one or more of R.sup.2 and
R.sup.3 are not branched alkyl groups, one or more of R.sup.2 and
R.sup.3 are a first linear alkyl group having 1 to 22 total carbon
atoms. R.sup.4 is selected from the group consisting of: a second
linear alkyl group having 1 to 6 carbon atoms, an aryl group, and
combinations thereof. In some embodiments, each branched alkyl
group has 12 to 18 total carbon atoms. In some embodiments, each
branched alkyl group has 14 to 18 total carbon atoms. In some
embodiments, one or more of R.sup.2 and R.sup.3 are each a first
linear alkyl group having 12 to 22 total carbon atoms; 1 to 6 total
carbon atoms or 7-11 total carbon atoms. In some embodiments,
R.sup.4 is independently a benzyl group, a methyl group, an ethyl
group, a propyl group, a butyl group, a pentyl group or a hexyl
group. In some other embodiments, one or more of R.sup.2 and
R.sup.3 are methyl and R.sup.4 is benzyl. In some other
embodiments, R.sup.2, R.sup.3 and R.sup.4 are each methyl.
[0004] In one embodiment, the present disclosure provides for an
organoclay composition comprising a mixture of (i) a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ and (ii) a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+. For the organoclay
composition comprising a phyllosilicate clay and quaternary
ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, one or more of R.sup.1,
R.sup.2 and R.sup.3 is each a mixture of branched alkyl groups each
having 12 to 22 total carbon atoms wherein the branched alkyl group
has one or more C.sub.1 to C.sub.3 alkyl groups distributed at
different carbon positions along a linear backbone of the branched
alkyl group.
[0005] For the organoclay composition comprising a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, one or more of R.sup.8,
R.sup.9 and R.sup.10 is each a third linear alkyl group having 12
to 22 total carbon atoms. In embodiments, when one or more of
R.sup.9 and R.sup.10 are not the third linear alkyl group then
R.sup.9 and R.sup.10 are each a fourth linear alkyl group having 1
to 22 total carbon atoms. R.sup.11 is selected from a fifth linear
alkyl group having 1 to 6 total carbon atoms, an arylgroup and
mixtures thereof.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0006] The present invention provides for organoclay compositions
where a phyllosilicate clay is exchanged with quaternary ammonium
ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+wherein at least one of
R.sup.1, R.sup.2 and R.sup.3 is a mixture of branched alkyl groups.
It has been unexpectedly found that such organoclay compositions
exhibit different properties compared to prior art organoclay
compositions exchanged with quaternary ammonium ions having a
formula of [NR.sup.aR.sup.bR.sup.cR.sup.d].sup.+ where at least one
of R.sup.a, R.sup.b, R.sup.c and R.sup.d is a not a mixture of
branched alkyl groups but a single branched alkyl group, such as
12-methyl stearyl, having a branching point located at a single
position along the linear backbone of the branched alkyl group.
[0007] In each of the embodiments, below "substantially free of
quaternary carbon atoms" shall mean that a quaternary carbon atom
is not detected by C.sup.13 NMR.
[0008] In one embodiment, the present disclosure provides for an
organoclay composition comprising: a phyllosilicate clay; and
quaternary ammonium ions having a formula of
[N--R.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein one or more of
R.sup.1, R.sup.2 and R.sup.3 is a mixture of branched alkyl groups,
each branched alkyl group having 12 to 22 total carbon atoms, a
linear backbone and one or more C.sub.1 to C.sub.3 branching alkyl
groups, wherein the branching alkyl groups are distributed at
different carbon positions along the linear backbone of the
branched alkyl group; and wherein when one or more of R.sup.2 and
R.sup.3 are not branched alkyl groups, one or more of R.sup.2 and
R.sup.3 are a first linear alkyl group having 1 to 22 total carbon
atoms. R.sup.4 is selected from the group consisting of: a second
linear alkyl group having 1 to 6 carbon atoms, an aryl group, and
combinations thereof. In some embodiments, each branched alkyl
group has 12 to 18 total carbon atoms. In some embodiments, each
branched alkyl group has 14 to 18 total carbon atoms. In some
embodiments, one or more of R.sup.2 and R.sup.3 are each a first
linear alkyl group having 12 to 22 total carbon atoms; 1 to 6 total
carbon atoms or 7-11 total carbon atoms. In some embodiments,
R.sup.4 is independently a benzyl group, a methyl group, an ethyl
group, a propyl group, a butyl group, a pentyl group or a hexyl
group. In some other embodiments, one or more of R.sup.2 and
R.sup.3 are methyl and R.sup.4 is benzyl. In some other
embodiments, R.sup.2, R.sup.3 and R.sup.4 are each methyl.
[0009] In some embodiments, the branched alkyl group, of one or
more of R.sup.1, R.sup.2 and R.sup.3, has an average number of
branches, per branched alkyl group, of at least 0.7. In some other
embodiments, the branched alkyl group, of one or more of R.sup.1,
R.sup.2 and R.sup.3, has an average number of branches per branched
alkyl group ranging from 0.7 to 7. In some other embodiments, the
branched alkyl group, of one or more of R.sup.1, R.sup.2 and
R.sup.3, has an average number of branches per branched alkyl group
ranging from 0.7 to 5. In some other embodiments, the branched
alkyl group, of one or more of R.sup.1, R.sup.2 and R.sup.3, has an
average number of branches per branched alkyl group ranging from
0.7 to 3. In each such embodiment, a methyl branch is at, least 50%
of the branching alkyl groups based on the total number of
branches.
[0010] In some embodiments, each branched alkyl group, of one or
more of R.sup.1, R.sup.2 and R.sup.3, has a distribution of
branching points distributed along the linear backbone of the
branched alkyl group ranging from a 2 carbon atom position on the
linear backbone, counting from a 1 carbon atom position which is
bonded to N.sup.+, to a .omega.-2 carbon atom position, where co is
a terminal carbon atom position on the linear backbone. In such
embodiments, a methyl branch is at least 50% of the branching alkyl
groups based on the total number of branches.
[0011] In some embodiments, the linear backbone, of the branched
alkyl group of one or more of R.sup.1, R.sup.2 and R.sup.3,
contains less 0.5 atom % of quaternary carbon atoms. In other
embodiments, the linear backbone, of the branched alkyl group one
or more of R.sup.1, R.sup.2 and R.sup.3, is substantially free of
quaternary carbon atoms.
[0012] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0013] In one embodiment, the present disclosure provides for an
organoclay composition comprising: a phyllosilicate clay; and
quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein R.sup.1 is a mixture
of branched alkyl groups, each branched alkyl group having 12 to 22
total carbon atoms, a linear backbone and one or more C.sub.1 to
C.sub.3 branching alkyl groups, wherein the branching alkyl groups
are distributed at different carbon positions along the linear
backbone of the branched alkyl group; and wherein R.sup.2 and
R.sup.3 are independently selected from the group consisting of: a
first linear alkyl group having 1 to 22 total carbon atoms, wherein
R.sup.4 is selected from the group consisting of: a second linear
alkyl group having 1 to 6 carbon atoms, an aryl group, and
combinations thereof. In some embodiments, each branched alkyl
group has 12 to 18 total carbon atoms. In some embodiments, each
branched alkyl group has 14 to 18 total carbon atoms. In some
embodiments, one or more of R.sup.2 and R.sup.3 are each the first
linear alkyl group having 12 to 22 total carbon atoms; 1 to 6 total
carbon atoms or 7-11 total carbon atoms. In some embodiments,
R.sup.4 is independently a benzyl group, a methyl group, an ethyl
group, a propyl group, a butyl group, a pentyl group or a hexyl
group. In some other embodiments, one or more of R.sup.2 and
R.sup.3 are methyl and R.sup.4 is benzyl. In some other
embodiments, R.sup.2, R.sup.3 and R.sup.4 are each methyl.
[0014] In some embodiments, the R.sup.1 branched alkyl group has an
average number of branches, per branched alkyl group, of at least
0.7. In some other embodiments, the R.sup.1 branched alkyl group
has an average number of branches per branched alkyl group ranging
from 0.7 to 7. In some other embodiments, the R.sup.1 branched
alkyl group has an average number of branches per branched alkyl
group ranging from 0.7 to 5. In some other embodiments, the R.sup.1
branched alkyl group has an average number of branches per branched
alkyl group ranging from 0.7 to 3. In each such embodiment, a
methyl branch is at least 50% of the branching alkyl groups based
on the total number of branches.
[0015] In some embodiments, the R.sup.1 branched alkyl group has a
distribution of branching points distributed along the linear
backbone of the branched alkyl group ranging from a 2 carbon atom
position on the linear backbone, counting from a 1 carbon atom
position which is bonded to N.sup.+, to a .omega.-2 carbon atom
position, where co is a terminal carbon atom position on the linear
backbone. In such embodiments, a methyl branch is at least 50% of
the branching alkyl groups based on the total number of
branches.
[0016] In some embodiments, the linear backbone, of the R.sup.1
branched alkyl group, contains less 0.5 atom % of quaternary carbon
atoms. In other embodiments, the linear backbone, of the R.sup.1
branched alkyl group, is substantially free of quaternary carbon
atoms.
[0017] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0018] In one embodiment, the present disclosure provides for an
organoclay composition comprising: a phyllosilicate clay; and
quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein R.sup.1 and R.sup.2
are a mixture of branched alkyl groups, each branched alkyl group
having 12 to 22 total carbon atoms, a linear backbone and one or
more C.sub.1 to C.sub.3 branching alkyl groups, wherein the
branching alkyl groups are distributed at different carbon
positions along the linear backbone of the branched alkyl group;
and wherein R.sup.3 is a first linear alkyl group having 1 to 22
total carbon atoms, R.sup.4 is selected from the group consisting
of: a second linear alkyl group having 1 to 6 total carbon atoms,
an aryl group, and combinations thereof. In some embodiments, each
branched alkyl group has 12 to 18 total carbon atoms. In some
embodiments, each branched alkyl group has 14 to 18 total carbon
atoms. In some embodiments, R.sup.3 is a first linear alkyl group
having 12 to 22 total carbon atoms; 1 to 6 total carbon atoms or
7-11 total carbon atoms. In some embodiments, R.sup.4 is
independently a benzyl group, a methyl group, an ethyl group, a
propyl group, a butyl group, a pentyl group or a hexyl group. In
some other embodiments, R.sup.3 is methyl and R.sup.4 is benzyl. In
some other embodiments, R.sup.3 and R.sup.4 are each methyl.
[0019] In some embodiments, the branched alkyl group, of R.sup.1
and R.sup.2, has an average number of branches, per branched alkyl
group, of at least 0.7. In some other embodiments, the branched
alkyl group, of R.sup.1 and R.sup.2, has an average number of
branches per branched alkyl group ranging from 0.7 to 7. In some
other embodiments, the branched alkyl group, of R.sup.1 and
R.sup.2, has an average number of branches per branched alkyl group
ranging from 0.7 to 5. In some other embodiments, the branched
alkyl group, of R.sup.1 and R.sup.2, has an average number of
branches per branched alkyl group ranging from 0.7 to 3. In each
such embodiment, a methyl branch is at least 50% of the branching
alkyl groups based on the total number of branches.
[0020] In some embodiments, each R.sup.1 and R.sup.2 branched alkyl
group has a distribution of branching points distributed along the
linear backbone of the branched alkyl group ranging from a 2 carbon
atom position on the linear backbone, counting from a 1 carbon atom
position which is bonded to N.sup.+, to a .omega.-2 carbon atom
position, where co is a terminal carbon atom position on the linear
backbone. In such embodiments, a methyl branch is at least 50% of
the branching alkyl groups based on the total number of
branches.
[0021] In some embodiments, the linear backbone, of each R.sup.1
and R.sup.2 branched alkyl group, contains less 0.5 atom % of
quaternary carbon atoms. In other embodiments, the linear backbone,
of each R.sup.1 and R.sup.2 branched alkyl group, is substantially
free of quaternary carbon atoms.
[0022] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0023] In one embodiment, the present disclosure provides for an
organoclay composition comprising: a phyllosilicate clay; and
quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, wherein R.sup.1, R.sup.2 and
R.sup.3 are each a mixture of branched alkyl groups, each branched
alkyl group having 12 to 22 total carbon atoms, a linear backbone
and one or more C.sub.1 to C.sub.3 branching alkyl groups, wherein
the branching alkyl groups are distributed at different carbon
positions along the linear backbone of the branched alkyl group;
and wherein R.sup.4 is selected from the group consisting of: a
second linear alkyl group having 1 to 6 carbon atoms, an alkyl, an
aryl group, and combinations thereof. In some embodiments, each
branched alkyl group has 12 to 18 carbon atoms. In some
embodiments, each branched alkyl group has 14 to 18 carbon atoms.
In some embodiments, R.sup.4 is independently a benzyl group, a
methyl group, an ethyl group, a propyl group, a butyl group, a
pentyl group or a hexyl group. In some other embodiments, R.sup.4
is benzyl. In some other embodiments, R.sup.4 is methyl.
[0024] In some embodiments, each R.sup.1, R.sup.2 and R.sup.3
branched alkyl group has an average number of branches, per
branched alkyl group, of at least 0.7. In some other embodiments,
each R.sup.1, R.sup.2 and R.sup.3 branched alkyl group has an
average number of branches per branched alkyl group ranging from
0.7 to 7. In some other embodiments, each R.sup.1, R.sup.2 and
R.sup.3 branched alkyl group has an average number of branches per
branched alkyl group ranging from 0.7 to 5. In some other
embodiments, each R.sup.1, R.sup.2 and R.sup.3 branched alkyl group
has an average number of branches per branched alkyl group ranging
from 0.7 to 3. In each such embodiment, a methyl branch is at least
50% of the branching alkyl groups based on the total number of
branches.
[0025] In some embodiments, each R.sup.1, R.sup.2 and R.sup.3
branched alkyl group has a distribution of branching points
distributed along the linear backbone of the branched alkyl group
ranging from a 2 carbon atom position on the linear backbone,
counting from a 1 carbon atom position which is bonded to N.sup.+,
to a .omega.-2 carbon atom position, where co is a terminal carbon
atom position on the linear backbone. In such embodiments, a methyl
branch is at least 50% of the branching alkyl groups based on the
total number of branches.
[0026] In some embodiments, the linear backbone, of each R.sup.1,
R.sup.2 and R.sup.3 branched alkyl group, contains less 0.5 atom %
of quaternary carbon atoms. In other embodiments, the linear
backbone, of each R.sup.1, R.sup.2 and R.sup.3 branched alkyl
group, is substantially free of quaternary carbon atoms.
[0027] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0028] In one embodiment, the present disclosure provides for an
organoclay composition comprising a mixture of (i) a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ and (ii) a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+. For the organoclay
composition comprising a phyllosilicate clay and quaternary
ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, one or more of R.sup.1,
R.sup.2 and R.sup.3 is each a mixture of branched alkyl groups each
having 12 to 22 total carbon atoms wherein the branched alkyl group
has one or more C.sub.1 to C.sub.3 alkyl groups distributed at
different carbon positions along a linear backbone of the branched
alkyl group. In some embodiments, the branched alkyl group may have
12 to 18 total carbon atoms or 14 to 18 total carbon atoms. In
embodiments, when one or more of R.sup.2 and R.sup.3 is not a
branched alkyl group, R.sup.2 and R.sup.3 are each a first linear
alkyl group having 1 to 22 total carbon atoms. R.sup.4 is selected
from the group consisting of a second linear alkyl group having 1
to 6 carbon atoms, an aryl group and combinations thereof. In some
embodiments, one or more of R.sup.2 and R.sup.3 are each the second
linear alkyl group having 12 to 22 total carbon atoms; 1 to 6 total
carbon atoms or 7-11 total carbon atoms; and R.sup.4 is
independently a benzyl group, a methyl group, an ethyl group, a
propyl group, a butyl group, a pentyl group or a hexyl group. In
some other embodiments, one or more of R.sup.2 and R.sup.3 are
methyl and R.sup.4 is benzyl. In some other embodiments, R.sup.2,
R.sup.3 and R.sup.4 are each methyl.
[0029] For the organoclay composition comprising a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, one or more of R.sup.8,
R.sup.9 and R.sup.10 is each a third linear alkyl group having 12
to 22 total carbon atoms. In embodiments, when one or more of
R.sup.9 and R.sup.10 are not the third linear alkyl group then
R.sup.9 and R.sup.10 are each a fourth linear alkyl group having 1
to 22 total carbon atoms. R.sup.11 is selected from a fifth linear
alkyl group having 1 to 6 total carbon atoms, an aryl group and
mixtures thereof. In some embodiments, the third linear alkyl group
may have 12 to 18 total carbon atoms or 14 to 18 total carbon
atoms. In some embodiments, one or more of R.sup.9 and R.sup.10 are
each the fourth linear alkyl group having 12 to 22 total carbon
atoms; 1 to 6 total carbon atoms or 7-11 total carbon atoms. In
some embodiments, R.sup.11 is independently a benzyl group, a
methyl group, an ethyl group, a propyl group, a butyl group, a
pentyl group or a hexyl group. In some other embodiments, one or
more of R.sup.9 and R.sup.10 are methyl and R.sup.11 is benzyl. In
some other embodiments, R.sup.9, R.sup.10 and R.sup.11 are each
methyl.
[0030] In some embodiments, each branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, of at least 0.7. In some other
embodiments, the branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 7. In some
other embodiments, the branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 5. In some
other embodiments, the branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 3. In each
such embodiment, a methyl branch is at least 50% of the branching
alkyl groups based on the total number of branches.
[0031] In some embodiments, each branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has a distribution of
branching points distributed along the linear backbone of the
branched alkyl group ranging from a 2 carbon atom position on the
linear backbone, counting from a 1 carbon atom position which is
bonded to N.sup.+, to a .omega.-2 carbon atom position, where co is
a terminal carbon atom position on the linear backbone. In such
embodiments, a methyl branch is at least 50% of the branching alkyl
groups based on the total number of branches.
[0032] In some embodiments, the linear backbone, of each branched
alkyl group of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, contains less
0.5 atom % of quaternary carbon atoms. In other embodiments, the
linear backbone, of each branched alkyl group of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, is substantially free of
quaternary carbon atoms.
[0033] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or an anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0034] In one embodiment, the present disclosure provides for an
organoclay composition comprising a mixture of (i) a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein R.sup.1 is a mixture
of branched alkyl groups having 12 to 22 total carbon atoms and
(ii) a phyllosilicate clay and quaternary ammonium ions having a
formula of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+wherein one or
more of R.sup.8, R.sup.9 and R.sup.10 is each a third linear alkyl
group having 12 to 22 total carbon atoms. In some embodiments of
the organoclay composition of an phyllosilicate clay and the
quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, branched alkyl group of
R.sup.1 has one or more C.sub.1 to C.sub.3 alkyl groups distributed
at different carbon positions along a linear backbone of the
branched alkyl group. In some embodiments, the branched alkyl
group, of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, may have 12 to 18
total carbon atoms or 14 to 18 total carbon atoms. In some
embodiments, one or more of R.sup.2 and R.sup.3 are each a first
linear alkyl group having 1 to 22 carbon atoms and R.sup.4 is
selected from: a second linear alkyl group having 1 to 6 total
carbon atoms, an aryl group. In some embodiments, one or more of
R.sup.2 and R.sup.3 are each the first linear alkyl group having 12
to 22 total carbon atoms, 1 to 6 total carbon atoms or 7-11 total
carbon atoms. In some embodiments, R.sup.4 is independently a
benzyl group, a methyl group, an ethyl group, a propyl group, a
butyl group, a pentyl group or a hexyl group. In some other
embodiments, one or more of R.sup.2 and R.sup.3 are methyl and
R.sup.4 is benzyl. In some other embodiments, R.sup.2, R.sup.3 and
R.sup.4 are each methyl.
[0035] In some embodiments of the organoclay composition of an
phyllosilicate clay and the quaternary ammonium ions having a
formula of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+ one or more of
R.sup.9 and R.sup.10 are each a fourth linear alkyl group having 1
to 22 total carbon atoms. R.sup.11 is selected from a fifth linear
alkyl group having 1 to 6 total carbon atoms, an aryl group, and
combinations thereof. In some embodiments, the third linear alkyl
group, of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, may have 12 to
18 total carbon atoms or 14 to 18 total carbon atoms. In some
embodiments, one or more of R.sup.9 and R.sup.10 are each the
fourth linear alkyl group having 12 to 22 total carbon atoms; 1 to
6 total carbon atoms or 7-11 total carbon atoms. In some
embodiments, R.sup.11 is independently a benzyl group, a methyl
group, an ethyl group, a propyl group, a butyl group, a pentyl
group or a hexyl group. In some other embodiments, one or more of
R.sup.9 and R.sup.10 are methyl and R.sup.11 is benzyl. In some
other embodiments, R.sup.9, R.sup.10 and R.sup.11 are each
methyl.
[0036] In some embodiments, the R.sup.1 branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, of at least 0.7. In some other
embodiments, the R.sup.1 branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 7. In some
other embodiments, the R.sup.1 branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 5. In some
other embodiments, the R.sup.1 branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 3. In each
such embodiment, a methyl branch is at least 50% of the branching
alkyl groups based on the total number of branches.
[0037] In some embodiments, the R.sup.1 branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has a distribution of
branching points distributed along the linear backbone of the
R.sup.1 branched alkyl group ranging from a 2 carbon atom position
on the linear backbone, counting from a 1 carbon atom position
which is bonded to N.sup.+, to a .omega.-2 carbon atom position,
where co is a terminal carbon atom position on the linear backbone.
In such embodiments, a methyl branch is at least 50% of the
branching alkyl groups based on the total number of branches.
[0038] In some embodiments, the linear backbone, of the R.sup.1
branched alkyl group of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+,
contains less 0.5 atom % of quaternary carbon atoms. In other
embodiments, the linear backbone, of the R.sup.1 branched alkyl
group of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, is substantially
free of quaternary carbon atoms.
[0039] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0040] In one embodiment, the present disclosure provides for an
organoclay composition comprising mixture of (i) a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein R.sup.1 and R.sup.2
are each a mixture of branched alkyl groups having 12 to 22 total
carbon atoms and (ii) a phyllosilicate clay and quaternary ammonium
ions having a formula of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+
wherein one or more of R.sup.8, R.sup.9 and R.sup.10 is each a
third linear alkyl group having 12 to 22 total carbon atoms. In
some embodiments of the organoclay composition comprising mixture
of (i) a phyllosilicate clay and quaternary ammonium ions having a
formula of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, the branched
alkyl group has one or more C.sub.1 to C.sub.3 alkyl groups
distributed at different carbon positions along a linear backbone
of the branched alkyl group. In some embodiments, the branched
alkyl group may have 12 to 18 total carbon atoms or 14 to 18 total
carbon atoms. R.sup.3 is a first linear alkyl group having 1 to 22
total carbon atoms, R.sup.4 is selected from a second linear alkyl
group having 1 to 6 carbon atoms, an arylgroup and mixtures
thereof. In some embodiments, R.sup.3 is the first linear alkyl
group having 12 to 22 total carbon atoms, 1 to 6 total carbon atoms
or 7-11 total carbon atoms; and R.sup.4 is independently a benzyl
group, a methyl group, an ethyl group, a propyl group, a butyl
group, a pentyl group or a hexyl group. In some other embodiments,
R.sup.3 is methyl and R.sup.4 is benzyl. In some other embodiments,
R.sup.3 and R.sup.4 are each methyl.
[0041] In some embodiments of the organoclay composition comprising
a phyllosilicate clay and quaternary ammonium ions having a formula
of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, the third linear alkyl
group may have 12 to 18 total carbon atoms or 14 to 18 total carbon
atoms. In some embodiments, one or more of R.sup.9 and R.sup.10 are
each a fourth linear alkyl group having 1 to 22 total carbon atoms.
In some embodiments, one or more of R.sup.9 and R.sup.10 are each
the fourth linear alkyl group having 12 to 22 total carbon atoms; 1
to 6 total carbon atoms or 7-11 total carbon atoms. In some
embodiments. R.sup.11 is selected from a fifth linear alkyl group
having 1 to 6 total carbon atoms, an aryl group and combinations
thereof. In some embodiments, R.sup.11 is independently a benzyl
group, a methyl group, an ethyl group, a propyl group, a butyl
group, a pentyl group or a hexyl group. In some other embodiments,
one or more of R.sup.9 and R.sup.10 are methyl and R.sup.11 is
benzyl. In some other embodiments, R.sup.9, R.sup.10 and R.sup.11
are each methyl.
[0042] In some embodiments, the R.sup.1 and R.sup.2 branched alkyl
groups, of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average
number of branches, per branched alkyl group, at least 0.7. In some
other embodiments, the R.sup.1 and R.sup.2 branched alkyl groups,
of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 7. In some
other embodiments, the R.sup.1 and R.sup.2 branched alkyl groups,
of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 5. In some
other embodiments, the R.sup.1 and R.sup.2 branched alkyl groups,
of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 3. In each
such embodiment, a methyl branch is at least 50% of the branching
alkyl groups based on the total number of branches.
[0043] In some embodiments, the R.sup.1 and R.sup.2 branched alkyl
groups, of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has a
distribution of branching points distributed along the linear
backbone of the R.sup.1 and R.sup.2 branched alkyl groups ranging
from a 2 carbon atom position on the linear backbone, counting from
a 1 carbon atom position which is bonded to N.sup.+, to a .omega.-2
carbon atom position, where co is a terminal carbon atom position
on the linear backbone. In such embodiments, a methyl branch is at
least 50% of the branching alkyl groups based on the total number
of branches.
[0044] In some embodiments, the linear backbone, of the R.sup.1 and
R.sup.2 branched alkyl groups of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, contains less 0.5 atom % of
quaternary carbon atoms. In other embodiments, the linear backbone,
of the R.sup.1 and R.sup.2 branched alkyl groups of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, is substantially free of
quaternary carbon atoms.
[0045] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0046] In one embodiment, the present disclosure provides for an
organoclay composition comprising mixture of (i) a phyllosilicate
clay and quaternary ammonium ions having a formula of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+ wherein R.sup.1, R.sup.2 and
R.sup.3 are each a mixture of branched alkyl groups having 12 to 22
total carbon atoms and R.sup.4 is a second linear alkyl group
having 1 to 6 carbon total atoms, an aryl and mixtures thereof and
(ii) a phyllosilicate clay and quaternary ammonium ions having a
formula of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, wherein one or
more of R.sup.8, R.sup.9 and R.sup.10 is each a third linear alkyl
group having 12 to 22 total carbon atoms and R.sup.11 is
independently selected from a fifth linear alkyl group having 1 to
6 total carbon atoms, an aryl and mixtures thereof.
[0047] In some embodiments, the branched alkyl group has one or
more C.sub.1 to C.sub.3 alkyl groups distributed at different
carbon positions along a linear backbone of the branched alkyl
group. In some embodiments, the branched alkyl group may have 12 to
18 total carbon atoms or 14 to 18 total carbon atoms. In some
embodiments, the third linear alkyl group may have 12 to 18 total
carbon atoms or 14 to 18 total carbon atoms. In some embodiments,
R.sup.4 is independently a benzyl group, a methyl group, an ethyl
group, a propyl group, a butyl group, a pentyl group or a hexyl
group. In some other embodiments, R.sup.4 is benzyl. In some other
embodiments, R.sup.4 is each methyl.
[0048] In some embodiments, one or more of R.sup.9 and R.sup.10 are
each a fourth linear alkyl group having 1 to 22 total carbon atoms.
In some embodiments, one or more of R.sup.9 and R.sup.10 are each
the fourth linear alkyl group having 12 to 22 total carbon atoms; 1
to 6 total carbon atoms or 7-11 total carbon atoms and R.sup.11 is
independently a benzyl group, a methyl group, an ethyl group, a
propyl group, a butyl group, a pentyl group or a hexyl group. In
some other embodiments, one or more of R.sup.9 and R.sup.10 are
methyl and R.sup.11 is benzyl. In some other embodiments, R.sup.9,
R.sup.10 and R.sup.11 are each methyl.
[0049] In some embodiments, the R.sup.1, R.sup.2 and R.sup.3
branched alkyl groups, of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+,
has an average number of branches, per branched alkyl group, at
least 0.7. In some other embodiments, the R.sup.1, R.sup.2 and
R.sup.3 branched alkyl groups, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 7. In some
other embodiments, the R.sup.1, R.sup.2 and R.sup.3 branched alkyl
groups, of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average
number of branches, per branched alkyl group, ranging from 0.7 to
5. In some other embodiments, the R.sup.1, R.sup.2 and R.sup.3
branched alkyl groups, of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+,
has an average number of branches, per branched alkyl group,
ranging from 0.7 to 3. In each such embodiment, a methyl branch is
at least 50% of the branching alkyl groups based on the total
number of branches.
[0050] In some embodiments, the R.sup.1, R.sup.2 and R.sup.3
branched alkyl groups, of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+,
has a distribution of branching points distributed along the linear
backbone of the R.sup.1, R.sup.2 and R.sup.3 branched alkyl groups
ranging from a 2 carbon atom position on the linear backbone,
counting from a 1 carbon atom position which is bonded to N.sup.+,
to a .omega.-2 carbon atom position, where co is a terminal carbon
atom position on the linear backbone. In such embodiments, a methyl
branch is at least 50% of the branching alkyl groups based on the
total number of branches.
[0051] In some embodiments, the linear backbone, of the R.sup.1,
R.sup.2 and R.sup.3 branched alkyl groups of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, contains less 0.5 atom % of
quaternary carbon atoms. In other embodiments, the linear backbone,
of the R.sup.1, R.sup.2 and R.sup.3 branched alkyl groups of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, is substantially free of
quaternary carbon atoms.
[0052] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0053] In one embodiment, the present disclosure provides for an
organoclay composition comprising a phyllosilicate clay and a
mixture of quaternary ammonium ions having formulas of
(i)[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, wherein one or more of
R.sup.1, R.sup.2 and R.sup.3 is each a mixture of branched alkyl
groups each having 12 to 22 total carbon atoms; 12 to 18 total
carbon atoms or 14 to 18 total carbon atoms and (ii)
[NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, wherein one or more of
R.sup.8, R.sup.9 and R.sup.10 is each a third linear alkyl group
having 12 to 22 total carbon atoms; 12 to 18 total carbon atoms or
14 to 18 total carbon atoms. In some embodiments, the branched
alkyl group has one or more C.sub.1 to C.sub.3 alkyl groups
distributed at different carbon positions along a linear backbone
of the branched alkyl group.
[0054] In some embodiments of quaternary ammonium ion having
formula of (i) [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, when one or
more of R.sup.2 and R.sup.3 are not branched alkyl groups, one or
more of R.sup.2 and R.sup.3 are each a first linear alkyl group
having 1 to 22 carbon total atoms. R.sup.4 is independently
selected from a second linear alkyl group having 1 to 22 total
carbon atoms, an aryl group and mixtures thereof. In some
embodiments, one or more of R.sup.2 and R.sup.3 are each the first
linear alkyl group having 12 to 22 total carbon atoms; 1 to 6 total
carbon atoms or 7-11 total carbon atoms; and R.sup.4 is
independently a benzyl group, a methyl group, an ethyl group, a
propyl group, a butyl group, a pentyl group or a hexyl group. In
some other embodiments, one or more of R.sup.2 and R.sup.3 are
methyl and R.sup.4 is benzyl. In some other embodiments, R.sup.2,
R.sup.3 and R.sup.4 are each methyl.
[0055] In some embodiments of the quaternary ammonium ion having
formula of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+wherein, R.sup.8
is the third linear alkyl group and R.sup.9 and R.sup.10 are each a
fourth linear alkyl group having 1 to 22 total carbon atoms, and
R.sup.11 is selected from a fifth linear alkyl group having 1 to 6
total carbon atoms, an aryl group and mixtures thereof. The fourth
linear alkyl group may have 12 to 22 total carbon atoms; 1 to 6
total carbon atoms or 7-11 total carbon atoms. R.sup.11 is
independently a benzyl group, a methyl group, an ethyl group, a
propyl group, a butyl group, a pentyl group or a hexyl group. In
some other embodiments, one or more of R.sup.9 and R.sup.10 are
methyl and R.sup.11 is benzyl. In some other embodiments, R.sup.9,
R.sup.10 and R.sup.11 are each methyl.
[0056] In some embodiments of the quaternary ammonium ion having
formula of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, R.sup.8 and
R.sup.9 are the third linear alkyl group and R.sup.10 is a fourth
linear alkyl group having 1 to 22 total carbon atoms, and R.sup.11
is selected from a fifth linear alkyl group having 1 to 6 total
carbon atoms, an aryl group and mixtures thereof. The fourth linear
alkyl group may have 12 to 22 total carbon atoms; 1 to 6 total
carbon atoms or 7-11 total carbon atoms. R.sup.11 is independently
a benzyl group, a methyl group, an ethyl group, a propyl group, a
butyl group, a pentyl group or a hexyl group. In some other
embodiments, one or more of R.sup.9 and R.sup.10 are methyl and
R.sup.11 is benzyl. In some other embodiments, R.sup.9, R.sup.10
and R.sup.11 are each methyl.
[0057] In some embodiments of the quaternary ammonium ion having
formula of [NR.sup.8R.sup.9R.sup.10R.sup.11].sup.+, R.sup.8,
R.sup.9 and R.sup.10 are the third linear alkyl group and R.sup.11
is selected from a fifth linear alkyl group having 1 to 6 total
carbon atoms, an aryl group and mixtures thereof. R.sup.11 is
independently a benzyl group, a methyl group, an ethyl group, a
propyl group, a butyl group, a pentyl group or a hexyl group. In
some other embodiments, one or more of R.sup.9 and R.sup.10 are
methyl and R.sup.11 is benzyl. In some other embodiments, R.sup.9,
R.sup.10 and R.sup.11 are each methyl.
[0058] In some embodiments, each branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, of at least 0.7. In some other
embodiments, the branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 7. In some
other embodiments, the branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 5. In some
other embodiments, the branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has an average number of
branches, per branched alkyl group, ranging from 0.7 to 3. In each
such embodiment, a methyl branch is at least 50% of the branching
alkyl groups based on the total number of branches.
[0059] In some embodiments, each branched alkyl group, of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, has a distribution of
branching points distributed along the linear backbone of the
branched alkyl group ranging from a 2 carbon atom position on the
linear backbone, counting from a 1 carbon atom position which is
bonded to N.sup.+, to a .omega.-2 carbon atom position, where co is
a terminal carbon atom position on the linear backbone. In such
embodiments, a methyl branch is at least 50% of the branching alkyl
groups based on the total number of branches.
[0060] In some embodiments, the linear backbone, of each branched
alkyl group of [NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, contains less
0.5 atom % of quaternary carbon atoms. In other embodiments, the
linear backbone, of each branched alkyl group of
[NR.sup.1R.sup.2R.sup.3R.sup.4].sup.+, is substantially free of
quaternary carbon atoms.
[0061] The organoclay composition may contain sufficient quaternary
ammonium ions to satisfy 50 to 150 percent of phyllosilicate cation
exchange capacity. In some embodiments, the quaternary ammonium
ions are in a concentration of 90 to 140 percent of phyllosilicate
cation exchange capacity wherein the positive charge of the
quaternary ion, in excess of the exchange capacity, is balanced by
an inorganic anion or organic anion or an anionic polymer. In some
embodiments, the quaternary ammonium ions are in a concentration of
95 to 130 percent of phyllosilicate cation exchange capacity
wherein the positive charge of the quaternary ion, in excess of the
exchange capacity, is balanced by an inorganic anion or organic
anion or anionic polymer. Examples of organic anions are found in
U.S. Pat. No. 5,718,841 which is incorporated by reference in its
entirety herein.
[0062] Preparation of Quaternary Ammonium Ions
[0063] Quaternary ammonium ions are obtained when fatty amines are
quaternized with alkylating agents such as methyl chloride, benzyl
chloride and the like. Note that the fatty amines may contain one
or more of alkyl chains per amine group. Various commercial
processes have been developed to produce fatty (long alkyl chain)
amines. Fatty acids can be readily converted into fatty amines
using a nitrile path as outlined in U.S. Pat. No. 5,634,969 for
instance. Fatty amines may also be prepared by reacting fatty
alcohol with aminating agents as disclosed in, for instance, U.S.
Pat. No. 4,683,336 or U.S. Pat. No. 4,994,620. Alternatively, long
alkyl chain internal- and/or terminal-olefins can be converted into
fatty amines via hydrobromination and reaction with aminating
agents as disclosed in U.S. Pat. No. 4,024,189 or U.S. Pat. No.
7,342,136. Said olefins can be obtained through oligomerization of
shorter olefins or by cracking larger paraffin wax type
molecules.
[0064] Fatty alkyl chains can be derived from a variety of natural
oleo-chemical sources. These sources can be used to supply raw
materials for either the nitrile or alcohol routes that yield fatty
amines. Palm or tallow fatty acids are popular raw materials for
organoclay manufacture because of cost and availability. The
majority of fatty acids that are derived from animal or plant
sources are linear. Fatty acids can be converted to fatty alchols
which then are used in the fatty alcohol route to make fatty
amines.
[0065] Saturated branched chain fatty acids can also be obtained
from natural fatty acids. Isostearic acid is a byproduct in the
dimer acid production but yields are relatively low making such
materials expensive. Recently, significant advances have been made
to isomerize natural feed stocks so that linear alkyl chains can be
converted into branched alkyl chains, U.S. Pat. No. 5,677,473.
Technology described in US 2011/0263884 discloses a high yield
skeletal isomerization process of unsaturated linear fatty acids
such as oleic acid. The process is highly selective and cost
effective (Ind. Eng. Chem. Res. 2012, 51, 12041-12045). Isostearic
acid typically is an isomeric mixture where the branching occurs at
various positions along the chain. Isostearic acids are
commercially available under the Century, Emersol, Emery, Oxocol
and Prisorine brand names.
[0066] Petrochemical processes have been developed that convert
natural gas or olefins such as ethylene, propylene and the like,
into fatty alkyl chains to prepare products such as, for example,
fatty alcohols. Cracking of paraffin can also yield long chain
olefins that can be converted into fatty alcohols via a
hydroformylation process. The performance of petrochemical based
linear primary alcohols and derivatives are in many applications
comparable to oleo-based alcohol products because the chemical
composition is essentially the same. However, the various
petrochemical processes can also yield chains with a certain degree
of branching. Ziegler, Fisher-Tropsch, Oxo and Querbet alcohols all
contain varying degrees of branched alkyl chains. Typical long
chain petrochemical alcohols that are commercially available are
NEODOL (Shell), EXXAL (Exxon) and ALFOL, SAFOL, MARLIPAL, ISALCHEM,
ALCHEM and LIAL (Sasol) alcohols. U.S. Pat. Nos. 5,849,960,
6,150,322, 7,781,390 and references therein describe processes and
compositions of linear as well as branched petrochemical alcohols.
The skeletal isomerization of long chain olefins into branched
olefins followed by selective hydroformylation yield branched
alcohols such as NEODOL 67, which is a highly branched alcohol
(Handbook of Detergents, Part F: Production). Hence, alkyl
branching can occur at any location around the alkyl chain, and the
branching group can be methyl, ethyl or even longer alkyl groups.
The average number of branching per alkyl chain can be determined
with .sup.1H and .sup.13C NMR analysis, while alkyl chain length
distribution can be estimated with GC. An average branching per
alkyl chain above unity means that some alkyl chains have more than
one branch per alkyl chain.
[0067] Phyllosilicate Clays
[0068] Phyllosilicate clay includes natural or synthetic
phyllosilicate clay, or mixtures thereof, which undergo ion
exchange reactions with quaternary ammonium cations forming an
organoclay. Representative natural phyllosilicate clays include
smectites, palygorskite, sepiolite, vermiculites, and micas.
Examples of smectite-type clays include montmorillonite, bentonite,
hectorite, saponite, stevensite, and beidellite. In some
embodiments, the phyllosilicate clay includes swelling clays such
as hectorite and Wyoming-type bentonite. In some embodiments, the
phyllosilicate clay is a mixture of hectorite and bentonite.
Bentonite and its properties are described at length in the chapter
entitled "Bentonite," in Can, D., ed. 1994, Industrial Minerals and
Rocks, 6th Edition (published by the Society For Mining, Metallurgy
and Exploration, Colorado). Smectite-type clays are well known in
the art and are commercially available from a variety of sources.
Phyllosilicate clays useful in accordance with the present
invention are described in detail in "Hydrous Phyllosilicates,
Reviews in Mineralogy, Volume 19, S. W. Bailey, editor." Other
useful literature can be found in Elsevier book series entitled
"Developments in Clay Science", in particular Volume 5 entitled
"Handbook of Clay Science."
[0069] Smectite clays which are layered, platy, hydrophilic
silicate materials. In the dry state, several nano-sized clay
layers are normally stacked on top of each other and these stacks,
or tactoids, are agglomerated into particles. However, the
platelets spontaneously separate from each other when dry clay
powder is dispersed in water. This "delamination of layers" is at
times also referred to as "exfoliation of layers." Smectite clay
layers carry a net negative charge on the platelets that is
neutralized by metal cations that are positioned on the surfaces of
the platelets. An organoclay is formed when the metal cations are
exchanged with organic cations. This reaction may be partially
completed or driven to completion. Organic surface treatment is
often necessary to improve the compatibility of the clay with
organic systems. Similar to "pristine" inorganic clays in water,
organoclays can delaminate in organic systems (solvents, polymers):
i.e. the clay layers that are now decorated with organic cations
are separated from each other when they are exfoliated in said
systems.
[0070] In an embodiment, the phyllosilicate clay may include crude
clay or beneficiated clay. The crude clay contains gangue or
non-clay material whereas the gangue material has been largely
removed from the beneficiated clay. In an embodiment using crude
clay, substantial cost savings may be realized because the steps
for the clay beneficiation process and conversion to the sodium
form are eliminated.
[0071] In some embodiments, the phyllosilicate clays include
synthetic phyllosilicate clays including synthetic vermiculite,
synthetic smectite, synthetic hectorite, synthetic fluorohectorite
and synthetic mica. The performance of synthetic clay based
organoclays may differ, either positively or negatively, from those
based on naturally occurring clays. These differences may be due to
chemical composition and homogeneity thereof, ion exchange
capacity, location of the ion exchange sites, impurities, surface
area, platelet size and distribution, and or other reasons. These
clays, also, may optionally be purified if desired.
[0072] The exchangable inorganic cations of the phyllosilicate clay
may be sodium or another cation. Preferably the exchangeable
cations will be sodium. In some embodiments, the exchangeable
cations can be a mixture of sodium, magnesium and calcium. In one
embodiment, the sodium form of the smectite clay may be used. To
prepare the sodium form of one embodiment, bentonite clay may be
converted to the sodium form by preparing an aqueous clay slurry
and passing the slurry through a bed of cation exchange resin in
the sodium form. In another embodiment, the sodium form of the
smectite clay may be prepared by mixing the clay with water and a
soluble sodium compound, such as sodium carbonate, sodium
hydroxide, etc.
[0073] In an embodiment, the phyllosilicate clay includes
smectite-type clay having a cation exchange capacity of at least 45
mMols per 100 grams of clay, 100% active clay basis, as determined
by the well-known ammonium acetate method or equivalent method. In
another embodiment, the phyllosilicate clay includes smectite-type
clay having a cation exchange capacity of at least 75 mMols per 100
grams of clay, 100% active clay basis.
[0074] The clay may be either sheared or non-sheared forms of the
above-listed smectite clays. In one embodiment, the sheared form of
the smectite clay may provide improved performance as compared to
non-sheared clay material. Elementis Specialties, Inc. and its
predecessor have issued patents describing the shearing of smectite
clay, as described in U.S. Pat. No. 4,695,402 and U.S. Pat. No.
4,742,098 which are incorporated herein by reference in their
entirety.
[0075] The organoclays, described herein, may be used in a variety
of applications. In some embodiments, the organoclays may be used a
rheology modifiers, anti-settling agents, sag control additives or
as adsorbants or as absorbants where the organoclay will host other
ion pairs within the gallery. In some embodiments, the organoclays
may be used as additives in greases, adhesives, sealants, inks,
consumer products such as lipstick, deodorant, nail polish and the
like.
[0076] In some embodiments, the organoclays, described herein, may
be used in coating systems where the organoclay is dispersible in
organic or solvent-based i.e. non-aqueous fluids to provide a wide
variety of rheological and viscosity-modifier properties to such
fluids. These non-aqueous fluids include oil-based paints and
coatings as well as oil-based inks, drilling fluids, caulks and
adhesives.
[0077] Coating Composition
[0078] In one embodiment, the organoclay compositions described
herein may be used to thicken a variety of organic and
solvent-based compositions. In certain embodiments, organoclay
compositions of the present invention are useful in non-aqueous
solvents including non-aqueous polymer solutions such as, for
example, a solution of an alkyd in mineral spirits, dispersions of
polymers in non-aqueous media (called non-aqueous dispersions), and
non-aqueous paints, paint strippers, adhesives, inks, sealants,
mastics, caulks, pigment dispersions, and pigment printing pastes
can be advantageously bodied, viscosified, or thickened, by this
invention. In certain embodiment, organoclay compositions described
herein are particularly useful, for example, in thickening
aliphatic and aromatic solvent-based compositions, and may also be
used in polar (ketones, alcohols, esters) based compositions. In
certain embodiments, the organoclay compositions according to the
present invention can be used, for example, in illustrative organic
compositions including aliphatic alkyd paints such as "trade sales"
paints, varnishes, epoxy-based paint, polyesters, modified alkyd
based paints and alkyd, polyester and acrylic bake enamels, such as
standard quality industrial paints, certain sealants and thermoset
systems such as unsaturated polyester resins formulations. In
certain embodiments, organoclay compositions according to the
present invention can be used, for example, in aromatic high solids
bake enamels which include systems based on alkyd/melamine,
acrylic/melamine, and polyester/melamine system including appliance
enamels, and equipment enamels. Additionally, the organoclay
compositions can be used in high solids air-dry enamels based on
alkyd and modified alkyd formulations.
[0079] In addition to aliphatic and aromatic solvent-based systems,
the organoclay compositions of the present invention may also be
used in petroleum-based and vegetable oil-based systems.
Illustrative vegetable oils include but are not limited to soybean
oil, rapeseed oil, canola oil, palm oil, rice bran oil and the
like. In one embodiment, the organoclay compositions of the present
invention can be dispersed into the organic composition to provide
improved viscosity characteristics.
[0080] The amount of the organoclay compositions used in a specific
instance is determined by numerous factors, including the type of
the organic solvent-based composition to be thickened, and the
level of thickening desired. On a weight basis, the amount of the
organoclay composition is generally from about 0.1 to about 1% by
weight, preferably from about 0.1 to about 0.7% by weight, and more
preferably from about 0.25 to about 0.5% by weight of the paint
system. The organoclay compositions of this invention may also be
used in combination with other rheological additives.
[0081] In one embodiment, such organoclays may be used as a
drilling fluid additive as set forth below.
[0082] Preparation of the Drilling Fluids
[0083] In some embodiments, compositions according to the present
invention may be used as an additive to oil- or synthetic-based
drilling fluids. In some embodiments, compositions according to the
present invention may be used as an additive for oil- or
synthetic-based invert emulsion drilling fluids employed in a
variety of drilling applications.
[0084] The term oil- or synthetic-based drilling fluid is defined
as a drilling fluid in which the continuous phase is hydrocarbon
based. Oil- or synthetic-based drilling fluids formulated with over
5% water or brine may be classified as oil- or synthetic-based
invert emulsion drilling fluids. In some embodiments, oil- or
synthetic-based invert emulsion drilling fluids may contain water
or brine as the discontinuous phase in any proportion up to about
5%, 10%, 15%, 20%, 25%, 30% or 50%. Oil muds may include invert
emulsion drilling fluids as well as all oil based drilling fluids
using synthetic, refined or natural hydrocarbon base as the
external phase.
[0085] According to some embodiments, a process for preparing
invert emulsion drilling fluids (oil muds) involves using a mixing
device to incorporate the individual components making up that
fluid. In some embodiments, primary and secondary emulsifiers
and/or wetting agents (surfactant mix) are added to the base oil
(continuous phase) under moderate agitation. The water phase,
typically a brine, may be added to the base oil/surfactant mix
along with alkalinity control agents and acid gas scavengers. In
some embodiments, rheological additives as well as fluid loss
control materials, weighting agents and corrosion inhibition
chemicals may also be included. The agitation may then be continued
to ensure dispersion of each ingredient and homogenize the
resulting fluidized mixture.
[0086] Base Oil/Continuous Phase
[0087] According to some embodiments, diesel oil, mineral oil,
synthetic oil, vegetable oil, fish oil, paraffinics, and/or
ester-based oils can all be used as single components or as
blends.
[0088] Brine Content
[0089] In some embodiments, water in the form of brine is often
used in forming the internal phase of the drilling fluids.
According to some embodiments, water can be defined as an aqueous
solution which can contain from about 10 to 350,000
parts-per-million of metal salts such as lithium, sodium,
potassium, magnesium, cesium, or calcium salts. In some
embodiments, brines used to form the internal phase of a drilling
fluid according to the present invention can also contain about 5%
to about 35% by weight calcium chloride and may contain various
amounts of other dissolved salts such as sodium bicarbonate, sodium
sulfate, sodium acetate, sodium borate, potassium chloride, sodium
chloride or formates (such as sodium, calcium, or cesium). In some
embodiments, glycols or glycerin can be used in place of or in
addition to brines.
[0090] In some embodiments, the ratio of water (brine) to oil in
the emulsions according to the present invention may provide as
high a brine content as possible while still maintaining a stable
emulsion. In some embodiments, suitable oil/brine ratios may be in
the range of about 97:3 to about 50:50. In some embodiments,
suitable oil/brine ratios may be in the range of about 90:10 to
about 60:40, or about 80:20 to about 70:30. In some embodiments,
the preferred oil/brine ratio may depend upon the particular oil
and mud weight. According to some embodiments, the water content of
a drilling fluid prepared according to the teachings of the
invention may have an aqueous (water) content of about 0 to 50
volume percent.
[0091] Emulsifiers
[0092] According to some embodiments, an emulsifier can also be
added to the drilling fluid in order to form a more stable
emulsion. The emulsifier may include organic acids, including but
not limited to the monocarboxyl alkanoic, alkenoic, or alkynoic
fatty acids containing from 3 to 20 carbon atoms, and mixtures
thereof. Examples of this group of acids include stearic, oleic,
caproic, capric and butyric acids. In some embodiments, adipic
acid, a member of the aliphatic dicarboxylic acids, can also be
used. According to some embodiments, suitable surfactants or
emulsifiers include fatty acid calcium salts and lecithin. In other
embodiments, suitable surfactants or emulsifiers include oxidized
tall oil, polyaminated fatty acids, and partial amides of fatty
acids.
[0093] In some embodiments, heterocyclic additives such as
imidazoline compounds may be used as emulsifiers and/or wetting
agents in the drilling muds. In other embodiments, alkylpyridines
may be used to as emulsifiers and/or wetting agents in the drilling
muds.
[0094] Industrially obtainable amine compounds for use as
emulsifiers may be derived from the epoxidation of olefinically
unsaturated hydrocarbon compounds with subsequent introduction of
the N function by addition to the epoxide group. The reaction of
the epoxidized intermediate components with primary or secondary
amines to form the corresponding alkanolamines may be of
significance in this regard. In some embodiments, polyamines,
particularly lower polyamines of the corresponding alkylenediamine
type, are also suitable for opening of the epoxide ring.
[0095] Another class of the oleophilic amine compounds that may be
suitable as emulsifiers are aminoamides derived from preferably
long-chain carboxylic acids and polyfunctional, particularly lower,
amines of the above-mentioned type. In some embodiments, at least
one of the amino functions is not bound in amide form, but remains
intact as a potentially salt-forming basic amino group. The basic
amino groups, where they are formed as secondary or tertiary amino
groups, may contain hydroxyalkyl substituents and, in particular,
lower hydroxyalkyl substituents containing up to five and in some
embodiments up to three carbon atoms in addition to the oleophilic
part of the molecule.
[0096] According to some embodiments, suitable N-basic starting
components for the preparation of such adducts containing
long-chain oleophilic molecule constituents may include but are not
limited to monoethanolamine or diethanolamine.
[0097] Weight Agents
[0098] In some embodiments, weighting materials are also used to
weight the drilling fluid additive to a desired density. In some
embodiments, the drilling fluid is weighted to a density of about 8
to about 18 pounds per gallon and greater. Suitable weighting
materials may include barite, ilmenite, calcium carbonate, iron
oxide and lead sulfide. In some embodiments, commercially available
barite is used as a weighting material.
[0099] Filtrate Reduces
[0100] In some embodiments, fluid loss control materials are added
to the drilling fluid to control the seepage of drilling fluid into
the formation. In some embodiments, fluid loss control materials
are lignite-based or asphalt-based. Suitable filtrate reducers may
include amine treated lignite, gilsonite and/or elastomers such as
styrene butadiene.
[0101] Blending Process
[0102] In some embodiments, drilling fluids may contain about 0.1
pounds to about 15 pounds of the drilling fluid additive per barrel
of fluids. In other embodiments, drilling fluids may contain about
0.1 pounds to about 10 pounds of the drilling fluid additive per
barrel of fluids, and in still other embodiments, drilling fluids
may contain about 0.1 pounds to about 5 pounds of the drilling
fluid additive per-barrel of fluids.
[0103] As shown above, a skilled artisan will readily recognize
that additional additives such as weighting agents, emulsifiers,
wetting agents, viscosifiers, fluid loss control agents, and other
agents can be used with a composition according to the present
invention. A number of other additives besides rheological
additives regulating viscosity and anti-settling properties can
also be used in the drilling fluid so as to obtain desired
application properties, such as, for example, anti-settling agents
and fluid loss-prevention additives.
[0104] Method of Use
[0105] In some embodiments, a drilling fluid additive may be added
to a drilling fluid. In some embodiments, the drilling fluid
additive may be added to a drilling fluid in combination with other
additives.
[0106] In some embodiments, a drilling fluid additive is added to a
drilling fluid in an amount of about 0.1 ppb to about 30 ppb. In
other embodiments, a drilling fluid additive is added to a drilling
fluid in an amount of about 0.25 ppb to about 15.0 ppb. In other
embodiments, a drilling fluid additive is added to a drilling fluid
in an amount of about 0.5 ppb to about 10.0 ppb. In some
embodiments, a drilling fluid additive is added to a drilling fluid
in an amount of about 2.5 ppb. In some embodiments, a drilling
fluid additive is added to a drilling fluid in an amount of about
5.0 ppb. In some embodiments, a drilling fluid additive is added to
a drilling fluid in an amount of about 10.0 ppb. In some
embodiments, a drilling fluid additive is added to a drilling fluid
in an amount of about 15.0 ppb. In some embodiments, a drilling
fluid additive is added to a drilling fluid in an amount of about
20.0 ppb. In some embodiments, a smaller amount of a drilling fluid
additive of the present invention is required to achieve comparable
rheological stability results as a known drilling fluid
additive.
[0107] The drilling fluid additive and drilling fluid may be
characterized by several rheological or hydraulic aspects, i.e.,
ECD, high shear rate viscosity, low shear rate viscosity, plastic
viscosity, regulating property viscosity and yield point, of a
drilling fluid. The rheological aspects may be determined using a
Fann viscometer as per standard procedures found in API RP13B-2
"Standard Procedures for Field Testing Oil-based Drilling Fluids".
Viscosity readings can be measured at 600 rpm, 300 rpm, 200 rpm,
100 rpm, 6 rpm and 3 rpm. ECD can be determined by: standard
hydraulics calculations found in API RP13D "Rheology and Hydraulics
of Oil-well Drilling Fluids." For the purposes of this invention
high shear rate viscosity ("HSR") corresponds to the viscosity
measured at 600 rpm as per API RP13B-2 procedures. For the purposes
of this invention, low shear rate viscosity ("LSR") corresponds to
the viscosity measured at 6 rpm as per API RP 13B-2 procedures.
Plastic viscosity ("PV") corresponds to the 600 rpm reading minus
the 300 rpm reading. Yield Point ("YP") corresponds to the 300 rpm
reading minus plastic viscosity.
[0108] In some embodiments, the addition of the drilling fluid
additive to a drilling fluid results in a substantially constant
ECD as temperature is varied over a range of about 120.degree. F.
to about 40.degree. F. For the purposes of this invention, a
substantially constant ECD may include a decrease or increase in
ECD over such temperature variation. In one embodiment, the
increase in ECD may include: up to 0.5%; up to 1%; up to 2%, up to
3%, up to 4%; up to 5%; up to 10%; up to 20%; up to 30%; and up to
40%. In one embodiment, the decrease in ECD may include: up to
0.5%; up to 1%; up to 2%, up to 3%, up to 4%; up to 5%; up to 10%;
up to 20%; up to 30%; and up to 40%. In one embodiment, the
increase in ECD may range from 1% up to 10%. In another embodiment,
the increase in ECD may range from 1% up to 5%.
[0109] In some embodiments, a drilling fluid according to the
present invention may have a lower viscosity at 40.degree. F. than
conventional muds formulated with sufficient conventional
organoclay to provide suspension at bottom hole temperatures. When
used in drilling operations, drilling fluids according to the
present invention may allow the use of a lower pumping power to
pump drilling muds through long distances, thereby reducing
down-hole pressures. Consequently, in some embodiments, whole mud
loss, fracturing and damage of the formation are all minimized. In
some embodiments, drilling fluids according to the present
invention may maintain the suspension characteristics typical of
higher levels of conventional organoclays at higher temperatures.
Such suspension characteristics may reduce the tendency of the mud
to sag. Sag may include the migration of weight material, resulting
in a higher density mud at a lower fluid fraction and a lower
density mud at a higher fluid fraction. A reduction of sag may be
valuable in both deep water drilling as well as conventional (non
deep water) drilling. The present invention may be particularly
useful in deep water drilling when the mud is cooled in the riser.
A mud using a drilling fluid additive according to the present
invention will maintain a reduced viscosity increase in the riser
when compared to drilling fluids containing conventional
rheological additives.
[0110] Blending Process
[0111] Drilling fluids preparations preferably contain between 1/4
and 20 pounds of the inventive mixture per barrel of fluids, more
preferred concentration is 1/4 to 10 pounds-per-barrel and most
preferably 1/4 to 5 pounds-per-barrel.
[0112] As shown above, a skilled artisan will readily recognize
that additional additives: weighting agents, emulsifiers, wetting
agents, viscosifiers, fluid loss control agents, and other agents
can be used with this invention. A number of other additives
besides rheological additives regulating viscosity and
anti-settling properties, providing other properties, can also be
used in the fluid so as to obtain desired application properties,
such as, for example, anti-settling agents and fluid
loss-prevention additives.
[0113] The drilling fluids of the present invention generally have
a lower high shear rate viscosity at 40.degree. F. than
conventional muds formulated with sufficient conventional
organoclay to provide suspension at bottom hole temperatures. When
used in drilling operations, the present drilling fluids allow the
use of a lower pumping power to pump drilling muds through long
distances, thereby reducing down-hole pressures. Consequently,
fluid loss, fracturing and damage of the formation are all
minimized. The present invention is particularly useful in deep
water drilling when the mud is cooled in the riser. A mud using the
described invention will maintain a reduced viscosity increase in
the riser when compared to drilling fluids containing conventional
rheological additives. One advantage is a stable rheological
profile which corresponds to a substantially constant equivalent
circulating density over a temperature range of about 120.degree.
F. to about 40.degree. F.
[0114] For the purposes of this application, the term "about" means
plus or minus 10%.
Examples
[0115] The following examples further describe and demonstrate
illustrative embodiments within the scope of the present invention.
The examples are given solely for illustration and are not to be
construed as limitations of this invention as many variations are
possible without departing from the spirit and scope thereof.
[0116] Quaternary ammonium compounds bearing branched alkyl groups
may be made with any known process. Non limiting synthesis examples
to prepare such branched quaternary ammonium compounds are given
below starting with branched alcohols as branched alkyl source or
branched fatty acids as the branched alkyl source.
Example 1
A. Synthesis of Benzyl Dimethyl (Branched Alkyl) Quaternary
Ammonium Chloride
[0117] Step 1: Synthesis of a (Branched Alkyl) Bromide from a
(Branched Alkyl) Alcohol.
[0118] In a 1 L, three-necked flask, fitted with a mechanical
stirrer, a thermometer, and a dropping funnel, is placed 113 g of
Neodol 67 alcohol. The alcohol is cooled to 0.degree. C. by
immersing the flask in an ice bath, and 55 g of phosphorus
tribromide is slowly added with stirring at such a rate as to keep
the temperature at 0.degree. C. (about two hours). The cooling bath
is removed, and stirring is continued until the mixture reaches
room temperature; it is then allowed to stand overnight.
[0119] To the flask was added 200 ml diethyl ether and 200 ml
deionized water. The pH of the mixture was adjusted to neutral with
5% potassium hydroxide under ice bath cooling. Subsequently the
solution was transferred to a reparatory funnel, the bottom layer
was drained and the top layer was washed with brine solution three
times. The top layer was then collected and filtered to remove
white precipitate; about 105 g of branched alkyl bromide was thus
collected after diethyl ether was removed by rota-evaporation.
[0120] Neodol 67 (Shell) mainly is a mixture of C.sub.16 and
C.sub.17 branched primary alcohols and is produced through
selective hydroformylation of branched olefins, which are derived
from ethylene. The hydrocarbon backbone of Neodol 67 is linear with
one or more methyl branching groups directly bonded to the
backbone. These methyl branches are distributed along the
backbone.
[0121] Step 2: Synthesis of a Dimethyl (Branched Alkyl) Tertiary
Amine
[0122] A total of 30.7 g of branched alkyl bromide (from Step 1)
was added to 147 ml of dimethylamine ethanolic solution. The
mixture is stirred at room temperature for 24 h, then a 10% aqueous
solution of sodium hydroxide is added and the mixture is extracted
three times with diethyl ether. The organic layers were washed,
dried and then concentrated.
[0123] Step 3: Synthesis of Benzyl Dimethyl (Branched Alkyl)
Quaternary Ammonium Chloride
[0124] A four-neck, 250 mL round-bottom flask equipped with a
reflux condenser, thermocouple and 2 glass stoppers is charged with
20 g of dimethyl (branched alkyl) tertiary amine (from Step 2), 5.8
g of benzyl chloride and roughly 100 mL isopropyl alcohol. Next,
3.5 g of sodium bicarbonate was added to the mixture under stirring
and the flask was kept at 75.degree. C. for 48 hours. Then the
reaction mixture was filtered hot over a Buchner funnel equipped
with filter paper to remove solid sodium bicarbonate. Ethanol was
removed by rota-evaporation, and the residue was dissolved in 100
ml of diethyl ether and extracted with three portions of 100 ml
deionized water, all aqueous extracts were then combined and water
was removed by rota-evaporation.
B. Organoclay Preparation
[0125] A sodium bentonite clay ore from Wyoming was dispersed in
water at about 5 wt. % clay solids. The crude clay slurry was mixed
overnight at ambient temperature and then centrifuged to yield a
beneficiated clay slurry. Roughly 30 wt % of the crude bentonite
clay was discarded during the beneficiation process, and the
resulting purified clay slurry was ion exchanged into the sodium
form prior to shearing with a Manton Gaulin homogenizer. The
beneficiated and sheared clay had a cation exchange capacity of
about 102 milliequivalents (meq.) per 100 grams clay as determined
by the methylene blue method. The clay slurry was diluted with
water to yield 2% clay solids at reaction and then heated to
65.degree. C. prior to reaction with a certain cation exchange
equivalent of benzyl dimethyl (branched alkyl) quaternary ammonium
chloride, per 100 grams of clay (dry basis). After reaction, the
organoclay was filtered, dried in a forced air oven set at
45.degree. C. and milled to a fine powder. The sample was labeled
3383-11-2.
Example 2
A. Synthesis of Dimethyl Di(Branched Alkyl) Quaternary Ammonium
Bromide
[0126] Using a branched petrochemical alcohol as the starting
material, a (branched alkyl) bromide and dimethyl (branched alkyl)
tertiary amine were prepared as described in steps 1 and 2 of
Example 1A.
[0127] A four-neck, 250 mL round-bottom flask equipped with a
reflux condenser, thermocouple and 2 glass stoppers is charged with
25 g of dimethyl (branched alkyl) tertiary amine, 15.2 g of
(branched alkyl) bromide and about 100 mL isopropyl alcohol. Next,
4.4 g of sodium bicarbonate was added to the mixture under stirring
and the flask was kept at 75.degree. C. for 120 hours or longer
until the amine value is below one. Then the reaction mixture was
filtered hot over a Buchner funnel equipped with filter paper to
remove solid sodium bicarbonate. Isopropyl alcohol was removed by
rota-evaporation. Purity of the final product was confirmed with
.sup.1H NMR.
B. Organoclay Preparation
[0128] An organoclay was prepared according to the procedure of
Example 1B using dimethyl di(branched alkyl) quaternary ammonium
bromide as the quaternary ammonium compound. The organoclay sample
was labeled 3279-36-1.
Example 3
A. Synthesis of Dimethyl Di(Branched Alkyl) Quaternary Ammonium
Bromide
[0129] A dimethyl di(branched alkyl) quaternary ammonium bromide
compound was prepared as described in Example 1A where the branched
alkyl group was derived from a branched fatty acid compound.
[0130] Step 1: Prisorene 3515 (Croda) isostearyl alcohol was used
in the synthesis of a branched alkyl bromide in a similar manner as
described in Example 1, Step A1. Prisorene 3515 is a fully
hydrogenated alcohol and is derived from isostearic acid, which is
a branched-chain fatty acid derived from vegetable oils or animal
fats. Isosteraric acid is not a single molecule, but a rich
isomeric mixture in which the branching occurs at different
positions along the alkyl chain. The branching is short, mostly
methylenic and multiple branching also occurs in small amounts.
[0131] Step 2: Synthesis of a Dimethyl (Branched Alkyl) Tertiary
Amine
[0132] The branched alkyl bromide, derived from isostearyl alcohol,
was mixed with dimethylamine ethanolic solution. The mixture is
stirred at room temperature for 24 h, then a 10% aqueous solution
of sodium hydroxide is added and the mixture is extracted three
times with diethyl ether. The organic layers were washed, dried and
then concentrated.
[0133] Step 3: Synthesis of Dimethyl Di(Branched Alkyl) Quaternary
Ammonium Bromide
[0134] The procedure of Example 2 was followed using the branched
alkyl bromide and dimethyl (branched alkyl) tertiary amine each
derived from isostearyl alcohol.
B. Organoclay Preparation
[0135] An organoclay was prepared according to Example 1B, using a
cation exchange equivalent of a dimethyl di(branched alkyl)
quaternary ammonium bromide compound where the branched alkyl
groups were obtained from an isostearyl alcohol. The sample was
labeled sample was labeled 3279-22-2.
Comparative Example 1
[0136] Following the procedure of Example 1B, a control organoclay
was prepared using a commercially available benzyl dimethyl
hydrogenated tallow quaternary ammonium chloride and this sample
was labeled as 3383-11-1.
Comparative Example 2
[0137] Following the procedure of Example 1B, a control organoclay
was prepared with commercially available dimethyl dihydrogenated
tallow ammonium chloride and this sample was labeled 3279-22-1.
Comparative Example 3
[0138] A polyamide was prepared as described in U.S. Pat. Nos.
7,345,010 and 7,799,742 each of which is incorporated by reference
in its entirety herein.
[0139] Testing of Branched Alkyl Compositions
[0140] Mud compositions were prepared for evaluation based on
Formulation 1 that contained a synthetic IAO as a base oil and were
weighted to 13 ppg with an oil:water ratio of 75:25.
TABLE-US-00001 TABLE 1 Formulation 1 Raw Materials Charge (g) Base
Oil: IAO 172 Primary Emulsifier: 10 MultiMixer Mix 2 min. 25%
Calcium Chloride 69 MultiMixer Mix 4 min. Brine Lime 10 MultiMixer
Mix 4 min. Tested Additive (See Tables) MultiMixer Mix 5 min.
Weighting Agent: Barite 270 MultiMixer Mix 30 min.
[0141] The mud compositions were dynamically aged using a roller
oven for 16 hours at 150.degree. F., then statically aged for 16
hrs at 40.degree. F., then were dynamically aged for 16 hours at
250.degree. F., 300.degree. F., and 350.degree. F. using a roller
oven. After the muds were water cooled for one hour, they were
mixed on a Hamilton beach MultiMixer for 10 minutes. Viscosity
measurements of the muds were measured using the Fann OFI-900 at
120.degree. F. initially and after each thermal cycle using test
procedures API RP 13B. For 40.degree. F. static aging, the test was
made at 40.degree. F.
Example 4
[0142] Organoclay 3279-36-1 (Example 2), was prepared using
Formulation 1 and tested as discussed above. The rheological
profile is shown below in Table 2.
TABLE-US-00002 TABLE 2 ppb 3279-36-1 Test Conditions 4 ppb 4 ppb 4
ppb 4 ppb 4 ppb 4 ppb OFI 900 Visc. Initial HR 150.degree. F. SA
40.degree. F. HR 250.degree. F. HR 300.degree. F. HR 350.degree. F.
@ 120.degree. F. 120.degree. F. Test 120.degree. F. Test 40.degree.
F. Test 120.degree. F. Test 120.degree. F. Test 120.degree. F. Test
600 RPM 66 58 115 69 66 44 Reading 300 RPM 42 36 68 43 41 23
Reading 200 RPM 33 28 51 34 32 13 Reading 100 RPM 23 19 33 24 22 8
Reading 6 RPM 10 8 11 10 9 2 Reading 3 RPM 9 7 9 9 9 1 Reading
Apparent 33 29 58 35 33 22 Visc., cPs Plastic 24 22 47 26 25 21
Visc., cPs Yield Point, 18 14 21 17 16 2 Lbs/100 ft.sup.2
Electrical 883 1067 1067 1059 932 581 Stability 10 Sec Gel 10 10 11
11 11 2 10 Min Gel -- 14 17 17 17 3
Example 5
[0143] Organoclay 3279-36-1 (Example 2), was prepared using
Formulation 1 and tested as discussed above. The rheological
profile is shown below in Table 3.
TABLE-US-00003 TABLE 3 ppb 3279-36-1 Test Conditions 7 ppb 7 ppb 7
ppb 7 ppb 7 ppb 7 ppb OFI 900 Visc. Initial HR 150.degree. F. SA
40.degree. F. HR 250.degree. F. HR 300.degree. F. HR 350.degree. F.
@ 120.degree. F. 120.degree. F. Test 120.degree. F. Test 40.degree.
F. Test 120.degree. F. Test 120.degree. F. Test 120.degree. F. Test
600 RPM 100 88 197 109 101 47 Reading 300 RPM 68 55 118 73 66 27
Reading 200 RPM 56 44 88 59 55 18 Reading 100 RPM 43 32 57 44 41 11
Reading 6 RPM 20 15 19 22 21 4 Reading 3 RPM 19 14 17 20 19 3
Reading Apparent 50 44 99 55 51 24 Visc., cPs Plastic 32 33 79 36
35 20 Visc., cPs Yield Point, 36 22 39 37 31 7 Lbs/100 ft.sup.2
Electrical 1128 1126 1126 1103 942 1012 Stability 10 Sec Gel 25 17
20 24 24 5 10 Min Gel -- 23 28 30 34 7 ECD (ppg) 13.6 13.4 13.8
13.7 13.6 13.2
Example 6
[0144] Organoclay 3279-36-1 (Example 2), was prepared using
Formulation 1 and tested as discussed above. The rheological
profile is shown below in Table 4.
TABLE-US-00004 TABLE 4 ppb 3279-36-1 Test Conditions 10 ppb 10 ppb
10 ppb 10 ppb 10 ppb 10 ppb OFI 900 Visc. Initial HR 150.degree. F.
SA 40.degree. F. HR 250.degree. F. HR 300.degree. F. HR 350.degree.
F. @ 120.degree. F. 120.degree. F. Test 120.degree. F. Test
40.degree. F. Test 120.degree. F. Test 120.degree. F. Test
120.degree. F. Test 600 RPM 177 155 290 198 175 81 Reading 300 RPM
122 100 179 137 122 47 Reading 200 RPM 101 80 138 113 102 37
Reading 100 RPM 76 57 94 83 76 25 Reading 6 RPM 37 27 35 39 38 10
Reading 3 RPM 35 24 31 36 36 9 Reading Apparent 89 78 145 99 88 41
Visc., cPs Plastic 55 55 111 31 53 34 Visc., cPs Yield Point, 67 45
68 76 69 13 Lbs/100 ft.sup.2 Electrical 1278 1291 1291 1331 860
1067 Stability 10 Sec Gel 45 26 36 41 41 12 10 Min Gel -- 34 51 49
55 17
Example 7
[0145] Organoclay 3279-36-1 (Example 2), and polyamide, comparative
example 3, was prepared using Formulation 1 and tested as discussed
above. The rheological profile is shown below in Table 5.
TABLE-US-00005 TABLE 5 ppb Comparative Example 3 2 ppb 2 ppb 2 ppb
2 ppb 2 ppb 2 ppb ppb 3279-36-1 Test Conditions 4 ppb 4 ppb 4 ppb 4
ppb 4 ppb 4 ppb OFI 900 Visc. Initial HR 150.degree. F. SA
40.degree. F. HR 250.degree. F. HR 300.degree. F. HR 350.degree. F.
@ 120.degree. F. 120 F..degree. Test 120.degree. F. Test 40.degree.
F. Test 120.degree. F. Test 120.degree. F. Test 120.degree. F. Test
600 RPM 89 95 182 85 70 46 Reading 300 RPM 61 62 109 56 43 26
Reading 200 RPM 50 49 81 46 33 20 Reading 100 RPM 37 35 49 34 22 12
Reading 6 RPM 19 17 14 19 12 4 Reading 3 RPM 18 15 12 18 11 4
Reading Apparent 45 48 91 43 35 23 Visc., cPs Plastic 28 33 73 29
27 20 Visc., cPs Yield Point, 33 29 36 27 16 6 Lbs/100 ft.sup.2
Electrical 1634 1322 1322 1159 725 494 Stability 10 Sec Gel 23 19
14 21 13 7 10 Min Gel -- 31 24 37 29 17 ECD (ppg) 13.6 13.5 13.8
13.5 13.3 13.2
Example 8
[0146] Organoclay 3279-22-1 (Comparative example 2) was prepared
using Formulation 1 and tested as discussed above. The rheological
profile is shown below in Table 6.
TABLE-US-00006 TABLE 6 ppb 3279-22-1 Test Conditions 7 ppb 7 ppb 7
ppb 7 ppb 7 ppb 7 ppb OFI 900 Visc. Initial HR 150.degree. F. SA
40.degree. F. HR 250 .degree. F. HR 300.degree. F. HR 350.degree.
F. @ 120.degree. F. 120.degree. F. Test 120.degree. F. Test
40.degree. F. Test 120.degree. F. Test 120.degree. F. Test
120.degree. F. Test 600 RPM 98 86 279 115 90 59 Reading 300 RPM 65
56 193 77 62 35 Reading 200 RPM 54 46 156 64 51 26 Reading 100 RPM
41 35 115 48 40 18 Reading 6 RPM 20 17 57 24 21 7 Reading 3 RPM 19
14 55 22 20 7 Reading Apparent 49 43 140 58 45 30 Visc., cPs
Plastic 33 30 86 38 28 24 Visc., cPs Yield Point, 32 26 107 39 34
11 Lbs/100 ft.sup.2 Electrical 1066 1339 1339 1193 1134 1166
Stability 10 Sec Gel 24 16 58 25 23 8 10 Min Gel -- 24 64 31 31 12
ECD (ppg) 13.6 13.5 14.8 13.7 13.6 13.3
Example 9
[0147] Organoclay 3279-22-1 (Comparative example 2) was prepared
using Formulation 1 and tested as discussed above. The rheological
profile is shown below in Table 7.
TABLE-US-00007 TABLE 7 ppb 3279-22-1 Test Conditions 4 ppb 4 ppb 4
ppb 4 ppb 4 ppb 4 ppb OFI 900 Visc. Initial HR 150.degree. F. SA
40.degree. F. HR 250.degree. F. HR 300.degree. F. HR 350.degree. F.
@ 120.degree. F. 120.degree. F. Test 120.degree. F. Test 40.degree.
F. Test 120.degree. F. Test 120.degree. F. Test 120.degree. F. Test
600 RPM 60 61 110 66 60 40 Reading 300 RPM 38 37 71 42 38 22
Reading 200 RPM 30 29 56 33 30 14 Reading 100 RPM 21 20 38 23 21 8
Reading 6 RPM 9 9 16 11 9 2 Reading 3 RPM 8 8 15 10 8 2 Reading
Apparent 30 31 55 33 30 20 Visc., cPs Plastic 22 24 39 24 22 18
Visc., cPs Yield Point, 16 13 32 18 16 4 Lbs/100 ft.sup.2
Electrical 939 1060 1060 1120 959 626 Stability 10 Sec Gel 11 9 16
12 12 2 10 Min Gel -- 14 21 16 15 4
Example 10
[0148] Organoclay 3279-22-1 (Comparative example 2) was prepared
using Formulation 1 and tested as discussed above. The rheological
profile is shown below in Table 8.
TABLE-US-00008 TABLE 8 ppb 3279-22-1 Test Conditions 10 ppb 10 ppb
10 ppb 10 ppb 10 ppb 10 ppb OFI 900 Visc. Initial HR 150.degree. F.
SA 40.degree. F. HR 250.degree. F. HR 300.degree. F. HR 350.degree.
F. @ 120.degree. F. 120.degree. F. Test 120.degree. F. Test
40.degree. F. Test 120.degree. F. Test 120.degree. F. Test
120.degree. F. Test 600 RPM 125 128 323 147 130 63 Reading 300 RPM
88 88 225 105 93 42 Reading 200 RPM 74 73 187 89 78 34 Reading 100
RPM 57 55 141 69 62 25 Reading 6 RPM 30 28 73 36 33 12 Reading 3
RPM 29 25 68 34 31 11 Reading Apparent 63 64 162 74 65 32 Visc.,
cPs Plastic 37 40 98 42 37 21 Visc., cPs Yield Point, 51 48 127 63
56 21 Lbs/100 ft.sup.2 Electrical 1278 1089 1089 1438 762 1176
Stability 10 Sec Gel 33 28 68 37 35 14 10 Min Gel -- 38 84 46 45
19
[0149] A summary of rheological properties for various compositions
prepared in Formula 1 is shown in Table 9.
TABLE-US-00009 TABLE 9 [Tested Sample] Mixture of Mixture of
Comparative Inventive Example Comparative Inventive Inventive
Examples 1 and 1 and Comparative Example 1 Example 1 Example 2 24/2
ppb Example 2 4/2 ppb Concentrations 7 ppb 7 ppb 7 ppb 7 ppb 7 ppb
7 ppb 4/2 ppb 4/2 ppb 4/2 ppb 4/2 ppb OFI 900 Visc. HR 150 F. SA 40
F. HR 150 F. SA 40 F. HR 150 F. SA 40 F. HR 150 F. SA 40 F. HR 150
F. SA 40 F. @ 120.degree. F. 120 F. Test 40 F. Test 120 F. Test 40
F. Test 120 F. Test 40 F. Test 120 F. Test 40 F. Test 120 F. Test
40 F. Test 600 RPM 86 279 88 197 83 196 87 178 95 182 Reading 300
RPM 56 193 55 118 55 116 56 105 62 109 Reading 200 RPM 46 156 44 88
45 87 44 78 49 81 Reading 100 RPM 35 115 32 57 34 57 31 49 35 49
Reading 6 RPM 17 57 15 19 17 21 17 19 17 14 Reading 3 RPM 14 55 14
17 15 19 15 17 15 12 Reading Apparent 43 140 44 99 42 98 44 89 48
91 Visc., cPs Plastic 30 86 33 79 28 80 31 73 33 73 Visc., cPs
Yield Point, 26 107 22 39 27 36 25 32 29 36 Lbs/100 ft.sup.2
Electrical 1339 1339 1126 1126 1314 1314 1541 1541 1322 1322
Stability 10 Sec Gel 18 58 17 20 18 20 18 18 19 14 10 Min Gel 24 62
23 28 25 29 30 29 31 24 ECD (ppg) 13.5 14.8 13.4 13.8 13.5 13.8
13.5 13.7 13.5 13.8
Example 11
[0150] A mixture of Comparative Example 2 and Comparative Example 3
was prepared using Formulation 1 and tested as discussed above. The
rheological profile is shown below in Table 10.
TABLE-US-00010 TABLE 10 Comparative Example 3 1 ppb 1 ppb 2 ppb 2
ppb 3 ppb 3 ppb Comparative Example 2 3 ppb 3 ppb 3 ppb 3 ppb 3 ppb
3 ppb OFI 900 Visc. Initial HR 150.degree. F. Initial HR
150.degree. F. Initial HR 150.degree. F. @ 120.degree. F.
120.degree. F. Test 120.degree. F. Test 120.degree. F. Test
120.degree. F. Test 120.degree. F. Test 120.degree. F. Test 600 RPM
84 71 75 66 63 61 Reading 300 RPM 52 45 46 40 40 38 Reading 200 RPM
40 35 37 31 32 30 Reading 100 RPM 27 25 26 21 22 21 Reading 6 RPM
14 13 12 9 11 11 Reading 3 RPM 13 12 11 8 10 10 Reading Apparent 42
36 38 33 32 31 Visc., cPs Plastic 32 26 29 26 23 23 Visc., cPs
Yield Point, 20 19 17 14 17 15 Lbs/100 ft.sup.2 Electrical 668 975
1465 1322 1543 1586 Stability 10 Sec Gel 20 17 15 11 13 12 10 Min
Gel -- 26 -- 18 -- 21
Example 12
[0151] A mixture of Comparative Example 2 and Comparative Example 3
was prepared using Formulation 1 and tested as discussed above. The
rheological profile is shown below in Table 11.
TABLE-US-00011 TABLE 11 Comparative Example 3 1 ppb 1 ppb 1 ppb 1
ppb 1 ppb 1 ppb Comparative Example 2 4 ppb 4 ppb 4 ppb 4 ppb 4 ppb
4 ppb OFI 900 Visc. Initial HR 150.degree. F. SA 40.degree. F. HR
250.degree. F. HR 300.degree. F. HR 350.degree. F. @ 120.degree. F.
120.degree. F. Test 120.degree. F. Test Test 120.degree. F. Test
120.degree. F. Test 120.degree. F. Test 600 RPM 87 74 133 82 69 42
Reading 300 RPM 57 48 82 55 44 24 Reading 200 RPM 45 38 63 44 35 16
Reading 100 RPM 32 28 43 33 25 10 Reading 6 RPM 17 14 19 18 13 3
Reading 3 RPM 16 13 18 17 12 3 Reading Apparent 44 37 67 41 35 21
Visc., cPs Plastic 30 26 51 27 25 18 Visc., cPs Yield Point, 27 22
31 28 19 6 Lbs/100 ft.sup.2 Electrical 822 1044 1044 879 738 476
Stability 10 Sec Gel 16 19 21 20 17 3 10 Min Gel 23 28 34 29 9 ECD
(ppg) 13.5 13.4 13.6 13.5 13.4 13.2
Example 13
[0152] A mixture of Comparative Example 2 and Comparative Example 3
was prepared using Formulation 1 and tested as discussed above. The
rheological profile is shown below in Table 12.
TABLE-US-00012 TABLE 12 Comparative Example 3 2 ppb 2 ppb 2 ppb 2
ppb 2 ppb 2 ppb Comparative Example 2 4 ppb 4 ppb 4 ppb 4 ppb 4 ppb
4 ppb OFI 900 Visc. Initial HR 150.degree. F. SA 40.degree. F. HR
250.degree. F. HR 300.degree. F. HR 350.degree. F. @ 120.degree. F.
120.degree. F. Test 120.degree. F. Test Test 120.degree. F. Test
120.degree. F. Test 120.degree. F. Test 600 RPM 105 87 178 83 68 47
Reading 300 RPM 70 56 105 54 43 27 Reading 200 RPM 57 44 78 43 34
21 Reading 100 RPM 42 31 49 31 24 13 Reading 6 RPM 23 17 19 17 14 5
Reading 3 RPM 22 15 17 15 13 5 Reading Apparent 53 44 89 42 34 24
Visc., cPs Plastic 35 31 73 29 25 20 Visc., cPs Yield Point, 35 25
32 25 18 7 Lbs/100 ft.sup.2 Electrical 1395 1541 1541 1044 616 466
Stability 10 Sec Gel 26 18 18 19 17 7 10 Min Gel -- 30 29 35 35 16
ECD (ppg) 13.6 13.5 13.7 13.5 13.4 13.2
Example 14
[0153] A mixture of Comparative Example 2 and Comparative Example 3
was prepared using Formulation 1 and tested as discussed above. The
rheological profile is shown below in Table 13.
TABLE-US-00013 TABLE 13 Comparative Example 3 3 ppb 3 ppb 3 ppb 3
ppb 3 ppb 3 ppb Comparative Example 2 4 ppb 4 ppb 4 ppb 4 ppb 4 ppb
4 ppb OFI 900 Visc. Initial HR 150.degree. F. SA 40.degree. F. HR
250.degree. F. HR 300.degree. F. HR 350.degree. F. @ 120.degree. F.
120.degree. F. Test 120.degree. F. Test Test 120.degree. F. Test
120.degree. F. Test 120.degree. F. Test 600 RPM 74 80 152 81 69 50
Reading 300 RPM 48 51 88 53 44 30 Reading 200 RPM 39 40 64 42 35 22
Reading 100 RPM 28 29 40 33 25 14 Reading 6 RPM 15 16 14 17 15 5
Reading 3 RPM 14 15 12 16 14 5 Reading Apparent 37 40 76 41 35 25
Visc., cPs Plastic 26 29 64 28 25 20 Visc., cPs Yield Point, 22 22
24 25 19 10 Lbs/100 ft.sup.2 Electrical 1670 1733 1733 1137 888 503
Stability 10 Sec Gel 18 18 14 21 22 8 10 Min Gel -- 30 35 38 19 ECD
(ppg) 13.4 13.4 13.6 13.5 13.4 13.3
Example 15
[0154] The effect of temperature on the viscosity of a 100% solids
epoxy coating was examined. The formulation of Table 14 was
prepared.
TABLE-US-00014 TABLE 14 Description: 800 g batch; 70 mm blade heavy
duty; 1 L stainless steel jacketed mixing pot Formula &
Procedure 1) Set water bath to 150.degree. F./65.degree. C. Add the
following 800 g materials (+/-0.1 g). Epon 828 238.37 Erysys GE-8
37.35 Organoclay additive 10.36 Methanol/Water (95/5) Polar
activator 3.31 2) Add while mixing @ 300-700 rpm. TI Pure R-900
76.15 Nicron 503 34.47 Minex 4 34.47 Heucophos ZPA (Heubach) 5.60
Wolastocoat 10 ES 121.65 Cimbar UF (Barytes) 139.47 3) Add the
following Let Down ingredients to mix pot (+/-0.1 g) Epon 828 96.94
Tint-Ayd HS 20317 1.87 4) Mix 10 min at 1000 rpm at 120.degree. F.
while covered. Total 800.00 Part B: Lite 2001LV Amine (AHEW 132)
100 Part A:28.25 Part B
[0155] The viscosity of the Part A system was measured at
72.degree. F. and at 40.degree. F. The sag of the Part A+Part B
expoxy coating was then measured. The results are shown in Table
15.
TABLE-US-00015 TABLE 15 Part "A" Part "A" Brookfield Brookfield
PART "A" + viscosity, cp viscosity, cp PART "B" measured at
72.degree. F. measured at 40 F. SAG, mils Blank 26800 164000 10
Comparative 48400 362000 18 example 1 Example 1 49600 238000 19
[0156] The data in Table 20 demonstrates that for the Part A
system, addition of the inventive organoclay of example 1 and the
organoclay of comparative example 1 results in an increased
viscosity and a thicker coating for the Part A+B system compared to
Part A and Part A+B in the absence of organoclay. Comparison of the
Part A system at 72.degree. F. versus 40.degree. F. shows that the
inventive organoclay, example 1, increases the viscosity but
advantageously not to the degree as the organoclay of comparative
example 1.
[0157] The present disclosure may be embodied in other specific
forms without departing from the spirit or essential attributes of
the invention. Accordingly, reference should be made to the
appended claims, rather than the foregoing specification, as
indicating the scope of the disclosure. Although the foregoing
description is directed to the preferred embodiments of the
disclosure, it is noted that other variations and modification will
be apparent to those skilled in the art, and may be made without
departing from the spirit or scope of the disclosure.
* * * * *